Stabilized pharmaceutical product

ABSTRACT

Use of an adsorbent and a sealed package (e.g. an overwrap) to protect a pharmaceutical product in a solid state in the presence of a reducing sugar.

This application is a continuation application of U.S. Ser. No.13/219,046, filed Aug. 26, 2011, now U.S. Pat. No. 8,163,299, which is acontinuation of Ser. No. 12/771,557, filed Apr. 30, 2010, now U.S. Pat.No. 8,029,811, which is a continuation application of U.S. Ser. No.11/259,495, filed Oct. 26, 2005, now U.S. Pat. No. 7,736,673, which is acontinuation of PCT/GB04/02249, filed May 27, 2004.

FIELD OF THE INVENTION

This invention relates to a stabilized pharmaceutical product comprisinga medicament. More particularly, it relates to a package and packagingmethod that utilizes an adsorbent material, such as a molecular sieve,that adsorbs or absorbs moisture in the inner local environment of animpermeable package, so as to prevent formation of Maillard productswhich result from chemical reactions between the medicament and areducing sugar in the medical device in the presence of moisture. Italso relates to a method of substantially maintaining the fine particlefraction of a medicament.

BACKGROUND OF THE INVENTION

Formoterol drug substances are known to be stable at ambient conditionsfor up to two years. However, when Formoterol is mixed with lactosedegradation is known to occur (Maillard reaction) because ofinteractions between the amino groups within the Formoterol molecule andthe lactose moiety.

Accordingly, what is needed is a stable pharmaceutical product in whichthe formation of Maillard degradation products are reduced or eliminatedin order to preserve the efficacy of the medicament contained within thepharmaceutical product.

The citation of any reference herein should not be construed as anadmission that such reference is available as “Prior Art” to the instantapplication.

SUMMARY OF THE INVENTION

Provided herein is a novel and useful stable pharmaceutical product inwhich the degradation of a medicament contained therein as a result of aMaillard reaction between the medicament and a pharmaceuticallyacceptable carrier, e.g. a reducing sugar, is reduced or eliminated.

Broadly, the present invention extends to a stable pharmaceuticalproduct that comprises (a) a pharmaceutical composition in the solidstate, which comprises a medicament and a reducing sugar, (b) aneffective amount of an adsorbent material, and (c) a sealed package thatis substantially impermeable to moisture, wherein the sealed package hasan enclosed volume within which the pharmaceutical composition and theadsorbent material are situated. The pharmaceutical composition may behoused in a dry powder inhaler that is located within the sealedpackage.

Furthermore, the present invention extends to a stable pharmaceuticalproduct comprising:

-   -   a) a pharmaceutical composition in the solid state comprising        formoterol and a reducing sugar;    -   b) an effective amount of an adsorbent material;    -   c) a sealed package substantially impermeable to moisture,        wherein the sealed package has an enclosed volume within which        the pharmaceutical composition and the adsorbent material are        situated.

The present invention also extends to a stable pharmaceutical productcomprising:

-   -   a) a pharmaceutical composition in the solid state comprising        formoterol fumarate dihydrate and non-micronized lactose        monohydrate, wherein the pharmaceutical composition is housed        within a dry powder inhaler;    -   b) an effective amount of an adsorbent material;    -   c) a sealed package substantially impermeable to moisture,        wherein the sealed package has an enclosed volume within which        the dry powder inhaler and the adsorbent material are situated.

Moreover, the present invention extends to a stable pharmaceuticalproduct comprising:

-   -   a) a pharmaceutical composition in the solid state comprising        formoterol fumarate dihydrate and non-micronized lactose        monohydrate, wherein the pharmaceutical composition is housed        within a dry powder inhaler;    -   b) an effective amount of an adsorbent material;    -   c) a sealed package substantially impermeable to moisture,        wherein the sealed package is a flexible laminate forms an        enclosed volume within which the dry powder inhaler and the        adsorbent material are situated.

The present invention further extends to method for preventing theformation of one or more Maillard products in a pharmaceutical product,due to a chemical reaction between a medicament of the pharmaceuticalproduct and a reducing sugar, wherein the pharmaceutical productcomprises:

-   -   a) a pharmaceutical composition in the solid state comprising        the medicament and a reducing sugar;    -   b) an effective amount of an adsorbent material;    -   c) a sealable package substantially impermeable to moisture,        wherein the sealable package has an enclosed volume within which        the pharmaceutical composition and the adsorbent material are        situated;    -   wherein the method comprises the steps of:    -   (i) positioning an effective amount of the adsorbent material        and the pharmaceutical composition within a sealable package;    -   (ii) sealing the sealable package so that the pharmaceutical        composition and adsorbent are in an enclosed volume within the        package; and    -   adsorbing moisture in the package so as to prevent the formation        of one or more Maillard products.

Numerous types of medicaments for treating a respiratory disease ordisorder have applications in a pharmaceutical composition of a stablepharmaceutical product or in a method of the present invention forpreventing the formation of one or more Maillard products in apharmaceutical product. An example of such a medicament is ananti-inflammatory, which includes corticosteroids such as mometasonefuroate, triamcinolone acetonide, flunisolide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone,prednisolone, and ciclesonide, to name only a few, a mast cellstabilizer such as Intal, Tilade, etc., and leukotriene modifiermedicament including, but certainly not limited to zafirlukast,montelukast sodium, and zileuton. Another example of an applicablemedicament is a beta2-agonist, which includes, but certainly is notlimited to salmeterol xinafoate, formoterol, albuterol, and salmeterol.Still another example is an anticholinergic, e.g. ipratropium bromide,tiotropium bromide, etc. Respiratory diseases or disorders that can betreated with a stable pharmaceutical product or a method for preventingthe formation of one or more Maillard products in a pharmaceuticalproduct of the present invention include, but certainly are not limitedto asthma and Chronic Obstructive Pulmonary Disease (COPD). Moreover, apharmaceutical composition can comprise a medicament alone or incombination with another medicament.

Naturally, various sizes of the particles of a medicament in a stablepharmaceutical product of the present invention or a method of thepresent invention for preventing the formation of one or more Maillardproducts in a pharmaceutical product have applications herein. Inparticular, the size of the particles can be about 0.1 μm to about 10μm. In a particular embodiment of a stable pharmaceutical product or amethod for preventing formation of one or more Maillard products of thepresent invention, greater than about 95% of a medicament has a particlesize of less than about 5 μm.

The present invention also extends to a method for substantiallymaintaining the fine particle fraction of a hydrophilic medicament in apharmaceutical composition, comprising the steps of:

-   (a) providing a pharmaceutical product that comprises:    -   (i) the pharmaceutical composition comprising the medicament and        a reducing sugar;    -   (ii) an effective amount of an adsorbent material;    -   (iii) a sealed package substantially impermeable to moisture        having an enclosed volume within which the pharmaceutical        composition and the adsorbent material are situated; and        (b) contacting the hydrophilic medicament in the pharmaceutical        composition with a hydrophobic material,        wherein the ratio of the hydrophobic material to the hydrophilic        medicament is at least 5:1.

Numerous hydrophilic medicaments have applications in a method forsubstantially maintaining fine particle fraction of the presentinvention. Examples include, but certainly are not limited to abeta2-agonist, such as salmeterol xinafoate, formoterol, and albuterol,to name only a few. Likewise, numerous hydrophobic materials haveapplications herein, including, but not limited to hydrophobicmedicaments for treating a respiratory disease or disorder such as ananti-inflammatory, e.g. a corticosteroid such as mometasone furoate,flunisolide, triamcinalone acetonide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone,prednisolone, ciclesonide, etc. In a particular embodiment, thehydrophilic medicament is formoterol and the hydrophobic material isciclesonide. In another particular embodiment, the hydrophilicmedicament is formoterol, and the hydrophobic medicament is acorticosteroid selected from the group consisting of mometasone furoate,flunisolide, triamcinalone acetonide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone, andprednisolone.

Furthermore, as disclosed above, the ratio of hydrophobic medicamentpresent to hydrophilic material present in a method for substantiallymaintaining fine particle fraction is at least 5:1. In a particularembodiment though, the ratio is about 10:1 to about 100:1.

In addition, particle size of the hydrophobic material and thehydrophilic medicament used in a method for substantially maintainingfine particle fraction of the present invention can vary, i.e. about 0.1μm to about 10 μm. More particularly, greater than about 95% of theparticles have a size of less than about 5 μm.

Furthermore, in a stable pharmaceutical product or in a method of thepresent invention as described herein, the adsorbent material can belocated in a variety of places. For example, the adsorbent material canbe situated in the enclosed volume between the package and dry powderinhaler, should it be present. Should the pharmaceutical composition behoused within a dry powder inhaler, the adsorbent material may also belocated within the dry powder inhaler. Another option is to have theadsorbent material incorporated into a polymer mixture used to producethe dry powder inhaler. As a result, the adsorbent material ismanufactured into a plastic component of the dry powder inhaler. Otherlocations at which the adsorbent material can be placed is into thesealed package, or even incorporated into an adhesive used to seal thesealed package, e.g. in a self-adhesive patch or tape. In a particularembodiment of a stable pharmaceutical product or a method of the presentinvention, the adsorbent material is located within in a porous sachetthat, in turn, is located within the sealed package.

Naturally, numerous adsorbent materials have applications in a stablepharmaceutical product or a method of the present invention, including amolecular sieve, an activated clay, charcoal, an activated alumina,silica, a zeolite, a bauxite, or any mixture of these materials, to nameonly a few. In particular embodiment of a stable pharmaceutical productor a method of the present invention, the adsorbent material is a 10 Å(Angstrom) molecular sieve. An effective amount of the adsorbentmaterial used in a stable pharmaceutical product or in a method of thepresent invention is that amount sufficient to reduce or eliminate theformation of Maillard products. One of ordinary skill can readilydetermine this amount for a particular embodiment of the presentinvention using routine laboratory techniques.

Moreover, a sealed package of a stable pharmaceutical product or amethod of the present invention can be produced from a variety ofmaterials, e.g. metal, glass, plastic, etc. Similarly, the shape of asealed package can vary. Examples of such shapes include, but certainlyare not limited to bottle, a bag, a drum box, and an irregularly shapedcontainer. In a particular embodiment of a stable pharmaceutical productor a method of the present invention, the sealed package is made from aflexible laminate that comprises a protective outer layer, a heatsealable layer, and a moisture impermeable layer located between theprotective outer layer and the heat sealable layer. Generally, anadhesive such as a polyester adhesive is located between each of thelayers. Numerous materials can be used for the protective layer,including paper or a polymer, such as polyester. Likewise, the moistureimpermeable layer can be made of a variety of materials, such as apolymer or a metal, e.g. aluminum, copper, steel, zinc, iron, tin,magnesium an amalgam, etc., to name only a few. The heat sealable layercan also be made of a variety of materials that can undergo heatsealing. In a particular embodiment of a stable pharmaceutical productor a method of the present invention, the flexible laminate comprising apolyester layer, an aluminum layer, and a polyethylene layer, whereinthe aluminum layer is located between the polyester and polyethylenelayers. The sealing of a package of a stable pharmaceutical product or amethod of the present invention can be accomplished in a variety ofways. More specifically, heat-sealing, gluing, welding, brazing,mechanical closures, mechanical clamps, or compression can hermeticallyseal a sealed package of a stable pharmaceutical product of the presentinvention or a method of the present invention.

Furthermore, various reducing sugars (as well as hydrates thereof) haveapplications in a stable pharmaceutical product or a method of thepresent invention, e.g. lactose, glucose, mannose, galactose, maltose,xylose, cellobiose, mellibiose, and maltotriose, to name only a few. Inparticular, a reducing sugar having applications herein is lactose. Moreparticularly, the reducing sugar is lactose monohydrate. A particulargrade of lactose monohydrate having applications herein is RESPITOSEML001 (DMV, Veghel, The Netherlands). Moreover, a reducing sugar havingapplications herein need not be micronised. In a particular embodiment,the reducing sugar has a mean particle size of about 41 μm. In addition,a reducing sugar of a stable pharmaceutical product or a method of thepresent invention can be non-micronized.

Moreover, in a particular embodiment of a stable pharmaceutical productor a method of the present invention, wherein a medicament is formoteroland the reducing sugar is lactose monohydrate, a pharmaceuticalcomposition comprises about 2969 μg to about 3016 μg of lactosemonohydrate per about 0.5 μg to about 4 μg of formoterol. In a moreparticular embodiment, a pharmaceutical composition comprises about 2969μg to about 3016 μg of lactose monohydrate per about 1 μg to about 2 μgof formoterol; and in a still more particular embodiment, apharmaceutical composition comprises about 2969 μg to about 3016 μg oflactose monohydrate per about 1 μg of formoterol.

Accordingly, it is an aspect of the present invention to provide astable pharmaceutical product comprising a medicament in which formationMaillard products will be reduced or prevented.

It is another aspect of the present invention to provide a method forprotecting the fine particle fraction of a medicament for pulmonarydelivery to a patient.

These and other aspects of the present invention will be betterappreciated by reference to the following drawings and DetailedDescription.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bar chart that shows an impurities comparison of a drypowdered inhaler (DPI) comprising Ciclesonide, Formoterol and lactose,wherein the DPI is wrapped, wrapped in the presence of molecular sieves,and unwrapped, at 6 and 10 weeks at 40 degrees Celsius and 75% relativehumidity.

FIG. 2 depicts a typical dry-power inhaler package according to thepresent invention.

FIG. 3 depicts two of a number of possible locations for the absorbentin a dry-power inhaler. For example, they could possibly be molded aspart of one of the plastic components, or could be provided in acontainer that is fixed to the inhaler.

DETAILED DESCRIPTION OF THE INVENTION

[1] A stable pharmaceutical product comprising:

-   -   a) a pharmaceutical composition in the solid state comprising a        medicament and a reducing sugar;    -   b) an effective amount of an adsorbent material; and    -   c) a sealed package substantially impermeable to moisture having        an enclosed volume within which the pharmaceutical composition        and the adsorbent material are situated.

[2] The stable pharmaceutical product according to embodiment [1],further comprising a dry powder inhaler that houses the pharmaceuticalcomposition.

[3] The stable pharmaceutical product according to embodiment [2],wherein the adsorbent material is situated in the enclosed volumebetween the sealed package and the dry powder inhaler.

[4] The stable pharmaceutical product according to embodiment [2],wherein the dry powder inhaler houses the adsorbent material.

[5]. The stable pharmaceutical product according to embodiment [2],wherein the adsorbent material is incorporated into a polymer mixtureand manufactured into a plastic component of the dry powder inhaler.

[6] The stable pharmaceutical product according to either of embodiments[1] or [2], wherein the adsorbent material is incorporated into thesealed package.

[7] The stable pharmaceutical product according to any one ofembodiments [1] to [4], wherein the adsorbent material is incorporatedinto an adhesive.

[8] The stable pharmaceutical product according to embodiment [7],wherein the adhesive is a self-adhesive patch or a tape.

[9]. The stable pharmaceutical product according to any one ofembodiments [1] to [4], wherein the adsorbent material is in a poroussachet.

[10] The stable pharmaceutical product according to any one ofembodiments [1] to [9], wherein the adsorbent material is selected fromthe group consisting of a molecular sieve, an activated clay, charcoal,an activated alumina, silica, a zeolite, a bauxite, and a mixturethereof.

[11] The stable pharmaceutical product according to embodiment [10],wherein the adsorbent material is 10 Å (Angstrom) molecular sieves.

[12] The stable pharmaceutical product according to any one ofembodiments [1] to [11], wherein the sealed package is made of metal,glass, or plastic, and the sealed package is selected from the groupconsisting of a bottle, a bag, a drum box, and an irregularly shapedcontainer.

[13] The stable pharmaceutical product according to embodiment [12],wherein the sealed package is a flexible laminate.

[14] The stable pharmaceutical product according to embodiment [13],wherein the flexible laminate comprises three layers: a protectivelayer, a heat sealable layer, and a moisture impermeable layer locatedbetween the protective layer and the heat sealable layer.

[15] The stable pharmaceutical product according to embodiment [14],wherein the protective layer is polyester, the moisture impermeablelayer is a metal selected from the group consisting of aluminum, copper,steel, zinc, iron, tin, magnesium, and a mixture thereof, and the heatsealable layer is polyethylene.

[16] The stable pharmaceutical product of embodiment [15], wherein themoisture impermeable layer is aluminum.

[17] The stable pharmaceutical product according to any one ofembodiments [1] to [16], wherein the sealed package is hermeticallysealed by heat-sealing, gluing, welding, brazing, mechanical closures,mechanical clamps, or compression.

[18] The stable pharmaceutical product according to any one ofembodiments [1] to [17], wherein the medicament is used in the treatmentof a respiratory disease.

[19] The stable pharmaceutical product according to embodiment [18],wherein the medicament comprises an anti-inflammatory, a beta2-agonist,an anticholinergic, or a combination thereof.

[20] The stable pharmaceutical product of embodiment [19], wherein theanti-inflammatory comprises a corticosteroid, a mast cell stabilizer, ora leukotriene modifier.

[21] The stable pharmaceutical product of embodiment [20], wherein thecorticosteroid is selected from the group consisting of mometasonefuroate, triamcinalone acetonide, flunisolide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone, andprednisolone.

[22] The stable pharmaceutical product of embodiment [20], wherein thecorticosteroid is ciclesonide.

[23] The stable pharmaceutical product of embodiment [20], wherein themast cell stabilizer comprises intal, tilade, or a combination thereof.

[24] The stable pharmaceutical product of embodiment [20], wherein theleukotriene modifier comprises zafirlukast, montelukast sodium,zileuton, or a combination thereof.

[25] The stable pharmaceutical product according of embodiment [19],wherein the beta2-agonist is selected from the group consisting ofsalmeterol xinafoate, formoterol, albuterol, and salmeterol.

[26] The stable pharmaceutical product of embodiment [19], wherein theanti-cholinergic is selected from the group consisting of ipratropiumbromide, tiotropium bromide, and a mixture thereof.

[27] The stable pharmaceutical product of embodiment [25], wherein themedicament is formoterol.

[28] The stable pharmaceutical product of embodiment [27], furthercomprising a corticosteroid.

[29] The stable pharmaceutical product according to embodiment [28],wherein the corticosteroid is ciclesonide.

[30] The stable pharmaceutical product according to any one ofembodiments [1] to [29], wherein the medicament has a particle size ofabout 0.1 μm to about 10 μm.

[31] The stable pharmaceutical product according to any one ofembodiments [1] to [30], wherein greater than about 95% of themedicament has a particle size of less than about 5 μm.

[32] The stable pharmaceutical product according to any one ofembodiments [1] to [31], wherein the reducing sugar is non-micronized.

[33] The stable pharmaceutical product according to any one ofembodiments [1] to [32], wherein the reducing sugar has a mean particlesize of about 41 μm.

[34] The stable pharmaceutical product according to any one ofembodiments [1] to [33], wherein the reducing sugar is selected from thegroup consisting of lactose, glucose, mannose, galactose, maltose,xylose, cellobiose, mellibiose, and maltotriose.

[35] The stable pharmaceutical product according to any one ofembodiments [1] to [34], wherein the reducing sugar is lactose.

[36] The stable pharmaceutical product according to embodiment [35],wherein the reducing sugar is lactose monohydrate.

[37] The stable pharmaceutical product of embodiment [36], wherein thelactose monohydrate is non-micronized.

[38] The stable pharmaceutical product according to either ofembodiments [36] or [37], wherein the pharmaceutical compositioncomprises about 2969 μg to about 3016 μg of lactose monohydrate perabout 0.5 μg to about 4 μg of formoterol.

[39] The stable pharmaceutical product according to embodiment [38],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per about 1 μg to about 2 μg offormoterol.

[40] The stable pharmaceutical product according embodiment [39],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per about 1 μg of formoterol.

[41] The stable pharmaceutical product according to any one ofembodiments [1] to [40], wherein the effective amount of the adsorbentmaterial is the amount sufficient to prevent or reduce formation ofMaillard products.

[42] A stable pharmaceutical product comprising:

-   -   a) a pharmaceutical composition in the solid state comprising        formoterol and a reducing sugar;    -   b) an effective amount of an adsorbent material; and    -   c) a sealed package substantially impermeable to moisture having        an enclosed volume within which the pharmaceutical composition        and the adsorbent material are situated.

[43] The stable pharmaceutical product of embodiment [42], wherein theformoterol is formoterol fumarate dihydrate.

[44] The stable pharmaceutical product of either of embodiments [42] or[43], wherein the reducing sugar is selected from the group consistingof lactose, glucose, mannose, galactose, maltose, xylose, cellobiose,mellibiose, and maltotriose.

[45] The stable pharmaceutical product of embodiment [44], wherein thereducing sugar is lactose.

[46] The stable pharmaceutical product of embodiment [45], wherein thereducing sugar is lactose monohydrate.

[47] The stable pharmaceutical product of embodiment [46], wherein thelactose monohydrate is non-micronized.

[48] The stable pharmaceutical product according to either ofEmbodiments [46] or [47], wherein the pharmaceutical compositioncomprises about 2969 μg to about 3016 μg of lactose monohydrate perabout 0.5 μg to about 4 μg of formoterol.

[49] The stable pharmaceutical product according to embodiment [48],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per about 1 μg to about 2 μg offormoterol.

[50] The stable pharmaceutical product according to embodiment [49],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per about 1 μg of formoterol.

[51] The stable pharmaceutical product according to any one ofembodiments [42] to [50], wherein the reducing sugar has a mean particlesize of about 41 μm.

[52] The stable pharmaceutical product of any of embodiments [42]-[51],wherein the pharmaceutical composition further comprises a secondmedicament for treating a respiratory disease or disorder.

[53] The stable pharmaceutical product of embodiment [52], wherein thesecond medicament comprises an anti-inflammatory, a beta2-agonist, ananticholinergic, or a combination thereof.

[54] The stable pharmaceutical product of embodiment [53], wherein theanti-inflammatory comprises a corticosteroid, a mast cell stabilizer, ora leukotriene modifier.

[55] The stable pharmaceutical product of embodiment [54], wherein thecorticosteroid is selected from the group consisting of mometasonefuroate, triamcinalone acetonide, flunisolide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone, andprednisolone.

[56] The stable pharmaceutical product of embodiment [55], furthercomprising formoterol.

[57] The stable pharmaceutical product of embodiment [54], wherein thecorticosteroid is ciclesonide.

[58] The stable pharmaceutical product of embodiment [57], furthercomprising a beta2-agonist selected from the group consisting ofsalmeterol xinafoate, albuterol and salmeterol.

[59]. The stable pharmaceutical product of embodiment [54], wherein themast cell stabilizer comprises intal, tilade, or a combination thereof.

[60] The stable pharmaceutical product of embodiment [54], wherein theleukotriene modifier comprises zafirlukast, montelukast sodium, orzileuton, or a combination thereof.

[61] The stable pharmaceutical product of embodiment [53], wherein thebeta2-agonist is selected from the group consisting of salmeterolxinafoate, formoterol, albuterol, and salmeterol.

[62] The stable pharmaceutical product of embodiment [53], wherein theanticholinergic is selected from the group consisting of ipratropiumbromide, tiotropium bromide, and a mixture thereof.

[63] The stable pharmaceutical product according to any one ofembodiments [42]-[63], wherein the adsorbent material is selected fromthe group consisting of a molecular sieve, an activated clay, charcoal,an activated alumina, silica, a zeolite, a bauxite, and a mixturethereof.

[64] The stable pharmaceutical product of embodiment [63], wherein theadsorbent material is 10 Å (Angstrom) molecular sieves.

[65] The stable pharmaceutical product of any of embodiments [42]-[64],further comprising a dry powder inhaler that houses the pharmaceuticalcomposition.

[66] The stable pharmaceutical product according to any one ofembodiments [42]-[65], wherein the sealed package is made of metal,glass, or plastic, and the sealed package is selected from the groupconsisting of a bottle, a bag, a drum box, and an irregularly shapedcontainer.

[67] The stable pharmaceutical product of any of embodiments [42]-[66],wherein the sealed package is a flexible laminate.

[68] The stable pharmaceutical product according to embodiment [67],wherein the flexible laminate comprises three layers: a protectivelayer, a heat sealable layer, and a moisture impermeable layer locatedbetween the protective layer and the heat sealable layer.

[69] The stable pharmaceutical product according to embodiment [68],wherein the protective layer is polyester, the moisture impermeablelayer is a metal selected from the group consisting of aluminum, copper,steel, zinc, iron, tin, magnesium, and a mixture thereof, and the heatsealable layer is polyethylene.

[70] The stable pharmaceutical product of embodiment [69], wherein themoisture impermeable layer is aluminum.

[71] The stable pharmaceutical product according to any one ofembodiments [42]-[70], wherein the sealed package is hermetically sealedby heat-sealing, gluing, welding, brazing, mechanical closures,mechanical clamps, or compression.

[72] The stable pharmaceutical product according to any one ofembodiments [42]-[71] wherein the pharmaceutical composition has aparticle size of about 0.1 μm to about 10 μm.

[73] The stable pharmaceutical product according to any one ofembodiments [42]-[72], wherein greater than about 95% of thepharmaceutical composition has a particle size of less than about 5 μm.

[74] The stable pharmaceutical product of any of embodiments [42]-[73],wherein the effective amount of the adsorbent material is that amount toprevent or reduce formation of Maillard products.

[75] A stable pharmaceutical product comprising:

-   -   a) a pharmaceutical composition in the solid state comprising        formoterol fumarate dihydrate and non-micronized lactose        monohydrate, wherein the pharmaceutical composition is housed        within a dry powder inhaler;    -   b) an effective amount of an adsorbent material;    -   c) a sealed package substantially impermeable to moisture,        wherein the sealed package has an enclosed volume within which        the dry powder inhaler and the adsorbent material are situated.

[76] The stable pharmaceutical product of embodiment [75], wherein thepharmaceutical composition further comprises a second medicament fortreating a respiratory disease or disorder.

[77] The stable pharmaceutical product of embodiment [76], wherein thesecond medicament comprises an anti-inflammatory, a beta2-agonist, ananticholinergic, or a combination thereof.

[78] The stable pharmaceutical product of embodiment [77], wherein theanti-inflammatory comprises a corticosteroid, a mast cell stabilizer, ora leukotriene modifier.

[79] The stable pharmaceutical product of embodiment [78], wherein thecorticosteroid is selected from the group consisting of mometasonefuroate, triamcinalone acetonide, flunisolide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone, andprednisolone.

[80] The stable pharmaceutical product of embodiment [78], wherein thecorticosteroid is ciclesonide.

[81] The stable pharmaceutical product of embodiment [78], wherein themast cell stabilizer comprises intal, tilade, or a combination thereof.

[82] The stable pharmaceutical product of embodiment [78], wherein theleukotriene modifier comprises zafirlukast, montelukast sodium,zileuton, or a combination thereof.

[83] The stable pharmaceutical product according of embodiment [77],wherein the beta2-agonist is selected from the group consisting ofsalmeterol xinafoate, albuterol, and salmeterol.

[84] The stable pharmaceutical product of embodiment [77], wherein theanticholinergic is selected from the group consisting of ipratropiumbromide, tiotropium bromide, and a combination thereof.

[85] The stable pharmaceutical product of any of embodiments or[75]-[84], wherein the pharmaceutical composition has a particle size ofabout 0.1 μm to about 10 μm.

[86] The stable pharmaceutical product of any of embodiments [75]-[85],wherein greater than about 95% of the pharmaceutical composition has aparticle size of less than about 5 μm.

[87] The stable pharmaceutical product according to any one ofembodiments [75]-[86], wherein the non-micronized lactose monohydratehas a mean particle size of about 41 μm.

[88] The stable pharmaceutical product according to any one ofembodiments [75]-[87], wherein the adsorbent material is a 10 Å(Angstrom) molecular sieve.

[89] The stable pharmaceutical product according to any of embodiments[75]-[88], wherein the pharmaceutical composition comprises about 2969μg to about 3016 μg of lactose monohydrate per about 0.5 μg to about 4μg of formoterol fumarate dihydrate.

[90] The stable pharmaceutical product according to embodiment [89],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per from about 1 μg to about 2 μg offormoterol fumarate dihydrate.

[91] The stable pharmaceutical product according to any one ofembodiments [66]-[81], wherein the pharmaceutical composition comprisesfrom about 2969 μg to about 3016 μg of lactose monohydrate per about 1μg of formoterol.

[92] The stable pharmaceutical product according to any one ofembodiments [75]-[91], wherein the sealed package is made of metal,glass, or plastic, and the sealed package is selected from the groupconsisting of a bottle, a bag, a drum box, and an irregularly shapedcontainer.

[93] The stable pharmaceutical product of embodiment [92], wherein thesealed package is a flexible laminate.

[94] The stable pharmaceutical product according to embodiment [93],wherein the flexible laminate comprises three layers: a protectivelayer, a heat sealable layer, and a moisture impermeable layer locatedbetween the protective layer and the heat sealable layer.

[95] The stable pharmaceutical product according to embodiment [94],wherein the protective layer is polyester, the moisture impermeablelayer is a metal selected from the group consisting of aluminum, copper,steel, zinc, iron, tin, magnesium, and a mixture thereof, and the heatsealable layer is polyethylene.

[96] The stable pharmaceutical product of embodiment [95], wherein themoisture impermeable layer is aluminum.

[97] The stable pharmaceutical product according to any one ofembodiments [75]-[96], wherein the sealed package is hermetically sealedby heat-sealing, gluing, welding, brazing, mechanical closures,mechanical clamps, or compression.

[98] The stable pharmaceutical product of any of embodiments [75]-[97],wherein the effective amount of the adsorbent material is that amount toprevent or reduce formation of Maillard products.

[99] A stable pharmaceutical product comprising:

-   -   a) a pharmaceutical composition in the solid state comprising        formoterol fumarate dihydrate and non-micronized lactose        monohydrate having a mean particle size of about 41 μm, wherein        the pharmaceutical composition is housed within a dry powder        inhaler;    -   b) an effective amount of an 10 Å molecular sieve; and    -   c) a sealed package substantially impermeable to moisture,        wherein the sealed package is a flexible laminate, and the        sealed package forms an enclosed volume within which the dry        powder inhaler and the adsorbent material are situated.

[100] The stable pharmaceutical product of embodiment [99], wherein thepharmaceutical composition further comprises a second medicament fortreating a respiratory disease or disorder.

[101] The stable pharmaceutical product of embodiment [100], wherein thesecond medicament comprises an anti-inflammatory, a beta2-agonist, ananticholinergic, or a combination thereof.

[102] The stable pharmaceutical product of embodiment [100], wherein theanti-inflammatory comprises a corticosteroid, a mast cell stabilizer, ora leukotriene modifier.

[103] The stable pharmaceutical product of embodiment [100], wherein thecorticosteroid is selected from the group consisting of mometasonefuroate, triamcinalone acetonide, flunisolide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone, andprednisolone.

[104] The stable pharmaceutical product of embodiment [100], wherein thecorticosteroid is ciclesonide.

[105] The stable pharmaceutical product of embodiment [100], wherein themast cell stabilizer comprises intal, tilade, or a combination thereof.

[106] The stable pharmaceutical product of embodiment [100], wherein theleukotriene modifier comprises zafirlukast, montelukast sodium,zileuton, or a combination thereof.

[107] The stable pharmaceutical product according of embodiment [99],wherein the beta2-agonist is selected from the group consisting ofsalmeterol xinafoate, formoterol, albuterol, and salmeterol.

[108] The stable pharmaceutical product of embodiment [99], wherein theanticholinergic is selected from the group consisting of ipratropiumbromide, tiotropium bromide, and a mixture thereof.

[109] The stable pharmaceutical product of any of embodiments[99]-[108], wherein the pharmaceutical composition has a particle sizeof about 0.1 μm to about 10 μm.

[110] The stable pharmaceutical product of any of embodiments[99]-[109], wherein greater than about 95% of the pharmaceuticalcomposition has a particle size of less than about 5 μm.

[111] The stable pharmaceutical product of any of embodiments[99]-[110], wherein the flexible laminate comprises three layers: aprotective layer, a heat sealable layer, and a moisture impermeablelayer located between the protective layer and the heat sealable layer.

[112]. The stable pharmaceutical product according to embodiment [111],wherein the protective layer is polyester, the moisture impermeablelayer is a metal selected from the group consisting of aluminum, copper,steel, zinc, iron, tin, magnesium, and a mixture thereof, and the heatsealable layer is polyethylene.

[113]. The stable pharmaceutical product according to embodiment [112],wherein the moisture impermeable layer is aluminum.

[114] The stable pharmaceutical product according to any one ofembodiments [99]-[113], wherein the flexible laminate is heat-sealed.

[115] The stable pharmaceutical product according to any of embodiments[99]-[114], wherein the pharmaceutical composition comprises about 2969μg to about 3016 μg of lactose monohydrate per about 0.5 μg to about 4μg of formoterol fumarate dihydrate.

[116] The stable pharmaceutical product according to embodiment [115],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per about 1 μg to about 2 μg offormoterol.

[117] The stable pharmaceutical product according to embodiment [116],wherein the pharmaceutical composition comprises about 2969 μg to about3016 μg of lactose monohydrate per about 1 μg of formoterol.

[118] The stable pharmaceutical product of any of embodiments[99]-[117], wherein the effective amount of the adsorbent material isthat amount to prevent or reduce formation of Maillard products.

[119] A method for preventing the formation of one or more Maillardproducts due to a chemical reaction between a medicament of apharmaceutical product and a reducing sugar, wherein the pharmaceuticalproduct comprises:

-   -   a) a pharmaceutical composition in the solid state comprising        the medicament and a reducing sugar;    -   b) an effective amount of an adsorbent material; and    -   c) a sealed package substantially impermeable to moisture and        having an enclosed volume within which the pharmaceutical        composition and the adsorbent material are situated;    -   wherein the method comprises the steps of:    -   (i) positioning an effective amount of the adsorbent material        and the pharmaceutical composition within a sealable package;    -   (ii) sealing the package to form the sealed package so that the        pharmaceutical composition and adsorbent are in an enclosed        volume within the sealed package; and    -   (iii) adsorbing moisture in the package so as to prevent        formation of one or more Maillard products.

[120] The method according to embodiment [119], wherein thepharmaceutical composition is in a dry powder inhaler.

The present invention is also based upon the discovery that,surprisingly and unexpectedly, the presence an excess amount of ahydrophobic material in a stable pharmaceutical product of the presentinvention substantially maintains the fine particle fraction of ahydrophilic medicament in the stable pharmaceutical product. As aresult, aggregation of hydrophilic medicament is limited, and efficientdry powder inhalation administration of fine particles of hydrophilicmedicament to the lung of patient can be promoted. Although under noobligation to explain this discovery, and certainly not intending to bebound to any hypothesis that may explain this discovery, it is believedthat this protective effect appears to occur when low dose hydrophilicmedicaments (such as formoterol fumarate dihydrate) are formulated withan excess amount of a hydrophobic material, (such as a corticosteroid asdescribed above), thereby limiting the potential for interaction of thehydrophilic medicament to the effects of ambient moisture vapor. As aresult, greater product performance stability is conferred upon thehydrophilic medicament when combined with an excess amount ofhydrophobic material than in the absence of the hydrophobic material.Hence, the present invention further extends to:

[121] A method for substantially maintaining fine particle fraction ahydrophilic medicament for treating a respiratory disease or disorder,comprising the steps of:

-   (a) providing a pharmaceutical product that comprises:    -   (i) a pharmaceutical composition comprising the hydrophilic        medicament and a reducing sugar;    -   (ii) an effective amount of an adsorbent material;    -   (iii) a sealed package substantially impermeable to moisture        having an enclosed volume within which the pharmaceutical        composition and the adsorbent material are situated; and-   (b) contacting the hydrophilic medicament in the pharmaceutical    composition with a hydrophobic material,    wherein the ratio of the hydrophobic material to the hydrophilic    material is at least 5:1.

[122] The method of embodiment [121], wherein the hydrophilic medicamentis a beta2-agonist.

[123] The method of embodiment [122], wherein the beta2-agonist isselected from the group consisting of salmeterol xinafoate, formoterol,and albuterol.

[124] The method embodiment [123], wherein the hydrophilic medicament isformoterol.

[125] The method of any of Embodiments [121]-[124], wherein thehydrophobic material is a hydrophobic medicament for treating arespiratory disease or disorder.

[126] The method of embodiment [125], wherein the hydrophobic medicamentis a corticosteroid.

[127] The method of embodiment [126], wherein the corticosteroid isselected from the group consisting of mometasone furoate, triamcinaloneacetonide, flunisolide, fluticasone propionate, budesonide,beclomethasone dipropionate, prednisone, betamethasone, cortisone,dexamethasone, hydrocortisone, methylprednisolone, and prednisolone.

[128] The method of embodiment [126], wherein the corticosteroid isciclesonide.

[129] The method of any of embodiments [121]-[128], wherein the ratio ofhydrophobic material to hydrophilic medicament is from about 10:1 toabout 100:1.

[130] The method of any of embodiments [121]-[129], wherein thehydrophobic material and the hydrophilic medicament have a particle sizeof about 0.1 μm to about 10 μm.

[131] The method of any of embodiments [121]-[130], wherein greater thanabout 95% of the hydrophobic material and the hydrophilic medicamenthave a particle size of less than about 5 μm.

[132] The method of any of embodiments [121]-[131], wherein the reducingsugar is selected from the group consisting of lactose, glucose,mannose, galactose, maltose, xylose, cellobiose, mellibiose, andmaltotriose.

[133] The method of embodiment [132], wherein the reducing sugar isnon-micronized.

[134] The method of embodiment [133], wherein the reducing sugar islactose monohydrate.

[135] The method of any of embodiments [121]-[134], wherein theadsorbent material is selected from the group consisting of a molecularsieve, an activated clay, charcoal, an activated alumina, silica, azeolite, a bauxite, and a mixture thereof.

[136] The method of any of embodiments [121]-[135], wherein theadsorbent material is 10 Å (Angstrom) molecular sieves.

[137] The method of any of embodiments [131]-[136], wherein thepharmaceutical composition is housed in a dry powder inhaler.

[138] The method of any of embodiments [121]-[137], wherein the sealedpackage is a flexible laminate.

[139] The method of embodiment [138], wherein the flexible laminatecomprises three layers: a protective layer, a heat sealable layer, and amoisture impermeable layer located between the protective layer and theheat sealable layer.

[140] The method of embodiment [139], wherein the protective layer ispolyester, the moisture impermeable layer is a metal selected from thegroup consisting of aluminum, copper, steel, zinc, iron, tin, magnesium,and a mixture thereof, and the heat sealable layer is polyethylene.

[141] The method of embodiment [140], wherein the moisture impermeablelayer is aluminum.

[142] The method according to any one of embodiments [121]-[141],wherein the sealed package is hermetically sealed by heat-sealing,gluing, welding, brazing, mechanical closures, mechanical clamps, orcompression.

[143] The method of any of embodiments [121]-[142], wherein theeffective amount of the adsorbent material is that amount to prevent orreduce formation of Maillard products.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Also, various featuresof the invention that are, for brevity, described in the context of asingle embodiment, may also be provided separately or in any suitablesubcombination.

Furthermore, numerous terms and phrases are used throughout the instantSpecification and Claims. Accordingly:

The term “stable” as used herein is intended to mean that a medicamentof a pharmaceutical product or a method of the present invention doesnot substantially decompose to form one or more Maillard products whenstored in a sealed package with an adsorbent material at 40 degreesCelsius at 75% relative humidity for at least 5 months. For example,there is substantially no Maillard product identified when themedicament is formoterol, and it is stored in a sealed package with anadsorbent material at about 40 degrees Celsius at about 75% relativehumidity for at least 5 months.

As used herein, the term “fine particle fraction” is that amount orpercentage of the particles of a pharmaceutical composition inhaled intothe lung of a patient that have an aerodynamic diameter of about 6microns or less

The “aerodynamic diameter” of a medicament inhaled into the lung of apatient can be approximated for all particles greater than 0.5 micronsusing the following equation:d _(pa) =d _(ps)√{square root over (p _(p))}  (1)where:

-   -   d_(pa)=Aerodynamic particle diameter, μm    -   d_(ps)=Stokes diameter, μm    -   p_(p)=Particle density, gm/cm³

As used herein, the term “hydrophobic material” refers to apharmaceutically acceptable material that tends not to combine withwater, or is incapable of dissolving in water. A particular example ofsuch a material is a hydrophobic medicament for treating a respiratorydisease or disorder, such as a corticosteroid, e.g. mometasone furoate,flunisolide, triamcinalone acetonide, fluticasone propionate,budesonide, beclomethasone dipropionate, prednisone, betamethasone,cortisone, dexamethasone, hydrocortisone, methylprednisolone,prednisolone, ciclesonide, etc. The hydrophobic material can also be acarrier or excipient in a pharmaceutical composition with thehydrophilic medicament.

As used herein, the phrase “pharmaceutically acceptable” refers tomolecular entities and compositions that are physiologically tolerableand do not typically produce an allergic or similar untoward reaction,such as gastric upset, dizziness and the like, when administered to ahuman. Preferably, as used herein, the term “pharmaceuticallyacceptable” means approved by a regulatory agency of the Federal or astate government or listed in the U.S. Pharmacopeia or other generallyrecognized pharmacopeia for use in animals, and more particularly inhumans.

As used herein, the term “hydrophilic medicament” refers to a medicamentthat readily absorbs water, or dissolves in water. A particular exampleof such a medicament having applications herein is a beta2-agonist, suchas salmeterol xinafoate, formoterol, and albuterol, to name only a few.

The term “reducing sugar” as used herein means a carbohydrate such aslactose, glucose, mannose, galactose, maltose, xylose, cellobiose,mellibiose, or maltotriose that undergoes oxidation and is able toreduce a metal ion to a lower oxidation state. In a particularembodiment of the present invention, the reducing sugar is lactose. Moreparticularly, the reducing sugar is lactose monohydrate, such asRESPITOSE ML001 (DMV, Veghel, The Netherlands). The particle size of thereducing sugar can be from about 0.5 μm to about 350 μm, from about 0.5μm to about 315 μm, from about 0.5 μm to about 150 μm, from about 0.5 μmto about 100 μm, from about 0.5 μm to about 45 μm, from about 0.5 μm toabout 25 μm, from about 0.5 μm to about 10 μm, from about 5 μm to about350 μm, from about 5 μm to about 315 μm, from about 5 μm to about 150μm, from about 5 μm to about 100 μm, from about 5 μm to about 45 μm,from about 5 μm to about 25 μm, from about 5 μm to about 10 μm, fromabout 10 μm to about 350 μm, from about 10 μm to about 315 μm, fromabout 10 μm to about 150 μm, from about 10 μm to about 100 μm, fromabout 10 μm to about 45 μm, from about 10 μm to about 25 μm, from about25 μm to about 350 μm, from about 25 μm to about 315 μm, from about 25μm to about 150 μm, from about 25 μm to about 100 μm, from about 25 μmto about 45 μm, from about 45 μm to about 350 μm, from about 45 μm toabout 315 μm, from about 45 μm to about 150 μm, from about 45 μm toabout 100 μm, from about 100 μm to about 350 μm from about 100 μm toabout 315 μm, from about 100 μm to about 150 μm, from about 150 μm toabout 350 μm, from about 150 μm to about 315 μm, from about 315 μm toabout 350 μm. In particular, the mean particle size is about 41 μm.Also, the reducing sugar need not be micronized.

The term “Maillard product” as used herein, means those products thatare formed via the Maillard reaction of the medicament with the reducingsugar in the presence of moisture.

The term “sealed package” as used herein is meant to encompass a sealedcontainer that is substantially impermeable to moisture. For example, asealed package may be made of metal, glass, or plastic, and is selectedfrom the group consisting of bottles, bags, drum boxes, and irregularlyshaped containers. In a particular embodiment, the package is aconventional flexible package (e.g. an overwrap) and its manufacturingis well within the knowledge of the people skilled in the art. Ingeneral, the flexible package is constructed from flat reels of laminatethat are folded or otherwise formed according to the packaging equipmenttechnology into a package by means of sealing and cutting. For example,as shown in FIG. 2, the sealed package has a substantially impermeableflexible package 10, in which a dry powder inhaler 20 and a molecularsieve 30 enclosed in a porous sachet 40 are sealed. In this embodimentthe package is constructed from a flat reel of flexible material that iscurled around into a long tube and a seal 14 is formed by heating(welding) the edges of the tube together. The cross seals 12 are formedby a straight heater bar that clamps the laminate tube before and afterthe package contents (i.e., the inhaler and the adsorbent sachet). Italso cuts the continuous tube into individual packs. As a result, thereis a long continuous seal 14 down the middle of the sealed package andthe cross seals 12 at both ends. Also, in FIG. 3, the sealed package hasa substantially impermeable flexible package 10, in which a dry powderinhaler 20 and adsorbent 30 are situated. The adsorbent 30 can molded aspart of one of the plastic components, or could be provided in acontainer that is fixed to the inhaler. In this embodiment, a sealedpackage is constructed from a flat reel of flexible material that iscurled around into a long tube and a seal 14 is formed by heating(welding) the edges of the tube together. The cross seals 12 are formedby a straight heater bar that clamps the laminate tube before and afterthe package contents. It also cuts the continuous tube into individualpacks. As a result, there is a long continuous seal 14 down the middleof the pack and the cross seals 12 at both ends.

Other sealed package types may include more or less seals according tothe desired shape of the container, which may be flat seals or crimped,and may include gussets. The seals may be formed by heating (welding) orby the use of pressure sensitive materials. In a further embodiment theflexible laminates may be formed using heat, pressure and/or vacuum intoblisters or pockets to contain the product and which are then sealed byheating.

A flexible sealed package is a particular type of package havingapplications herein. However, other types of enclosures or containersmay be suitable, whether flexible or inflexible, provided that theenclosure chosen is substantially impermeable to moisture ingress.

A particular flexible material for making a flexible sealed package is alaminate, although other materials may also be satisfactorily employed.The main limitation is that the laminate must be substantiallyimpermeable to atmosphere moisture.

The laminate used in making packages generally consists of severallayers of materials either co-extruded or bonded together to form anapparently single film of “laminate”. As an example, a suitable laminatemay have three layers adhesively laminated to each other: protectiveouter layer, a heat sealable layer, and a moisture impermeable layerlocated between the protective outer layer and the heat sealable layer.Generally, an adhesive such as a polyester adhesive is located betweeneach of the layers. Numerous materials can be used for the protectivelayer, including paper or a polymer, such as polyester. The heatsealable layer can also be made of a variety of materials that canundergo heat sealing. For example, Pharmaflex Ltd., part of Alcan inc.(Cramlington, Northumberland, England) supplies a laminate film havingthree layers: polyester (12 μm), aluminum foil (9 μm) and polyethylene(50 μm) (product catalog LMP-F BRI/72/H1). Also, another suitablelaminate consists of polyester (12 μm), aluminium foil (9 μm) and linearlow-density polyethylene (40 μm), wherein the three layers are extrusionlaminated together using bonding layers that include polyethylene basedpolymers. This laminate is available from Amcor Flexibles, Lund, Sweden.The heat sealable layer forms the inside of the package (in contact withthe medical device) and is normally a thermoplastic layer. A commonmaterial for the inner layer is polyethylene, but other polyolefinic orcyclo-olefinic materials may also be used. In addition, specialistmaterials such as ionomers are also frequently used for making the innerlayer, for example, the ionomer under the tradename SURLYN.

The moisture impermeable layer is situated between the inner heatsealable layer and the outer protective layer, and providesimpermeability to the pack. Aluminum foil is commonly used for themoisture impermeable layer, although any other metals capable of beingrolled into thin sheets can also be satisfactorily used. A typicalthickness for the aluminum foil layer is about 8 or 9 microns.Alternatively, the barrier layer may be metalized film, made up of tin,iron, zinc, magnesium or other metals coated by vacuum deposition orsputtering onto a polymeric sheet. In a particular embodiment, aluminumis used as the moisture impermeable layer.

The outer protective layer normally provides support, impact resistance,and protection for the moisture impermeable layer and general robustnessto the pack. A commonly used material for the protective layer ispolyester, although other material, such as paper, may also be used.

The present invention is intended to encompass the free acids, freebases, salts, amines and various hydrate forms including semi-hydrateforms of such medicaments and is particularly directed towardspharmaceutically acceptable formulations of such medicaments which areformulated in combination with pharmaceutically acceptable excipientmaterials generally known to those skilled in the art, particularlywithout other additives such as preservatives. Thus, as used herein, theterm “formoterol” refers to any optically active isomer of formoterol,as well as to any hydrate of formoterol. Optionally, a pharmaceuticalcomposition can comprise a medicament or a combination of more than onemedicament.

A medicament may also be compounded with a variety of additives, such assurfactants or emulsifiers, and vehicles.

A particular medicament formulation consists essentially of amedicament, or a physiologically acceptable salt or solvate thereof,optionally in combination with one or more other pharmacologicallyactive agents.

Optionally, the formulations according to the invention may furthercomprise one or more antioxidants. The antioxidant may be selected fromthe group consisting of tocopherol, methyl paraben, ethyl paraben andascorbic acid and mixtures thereof. A particular antioxidant istocopherol.

As used herein, the term “dry powder inhaler” (DPI) refers to a breathactivated device for administering a dry powder into the lungs of asubject. Dry powder inhalers having applications herein include, butcertainly are not limited to the TWISTHALER produced by Schering PloughCorp., Kenilworth, N.J.; the SPINHALER produced by Fisons, UK; theROTAHALER produced by GlaxoSmithkline; the ULTRAHALER produced byAventis Pharma, UK; the TURBUHALER produced by Astrazeneca Corp.; andthe ACCUHALER produced by GlaxoSmithkline, to name only a few. Aparticular dry powder inhaler having applications herein is theULTRAHALER.

The term “adsorbent” as used herein is meant to encompass a substancethat has the ability to condense or hold molecules of other substanceson its surface or in its inner structure, an activity often referred as“adsorbing” or “absorbing”, respectively. Examples of such adsorbentsinclude activated carbon, alumina, bauxite, charcoal, zeolites, silicagel, molecular sieves, activated clays, bauxite, and mixtures thereof.

The present invention is not limited to any specific adsorbents.Choosing a proper adsorbent for moisture is well within the ordinaryskill of the artisans in the field. They can make an initial choicebased on their knowledge and experience (for example, weighing thefactors such as the pore size of an adsorbent (as well as any electroniccharges it carries) and then conduct routine tests to determine theactual effectiveness, and the effective amount, of the chosen adsorbentagainst a given amount of moisture. They may need to repeat the processuntil a proper adsorbent is found. One of the tests for finding aneffective adsorbent against Maillard product formation is describedherein and can be adopted by people skilled in the art to determine theactual effectiveness of any adsorbent, currently existing or to bedeveloped in the future, against formation of Maillard product caused bythe interaction of the medicament and reduced sugar, in the presence ofmoisture.

There are numerous ways in which the absorbent material can be presentin the pharmaceutical product. For example, the adsorbent can beincorporated into a polymer mixture and manufactured into a plasticcomponent of the medical device. Also, the adsorbent can be incorporatedinto a polymer mixture and manufactured into plastic sheeting used inthe packaging of the device. The adsorbent can be incorporated into apolymer mixture in the same, or similar, manner as desiccant polymermixtures disclosed in U.S. Pat. Nos. 5,911,937; 3,245,946; 4,013,566;4,407,897; 4,425,410; 4,464,443; 5,078,909; and 4,792,484, which areincorporated herein by reference in their entireties. Although thesepatents disclose desiccants, it is foreseeable that the methods ofmanufacturing these plastics could be used to manufacture an adsorbentmaterial used in the present invention. For example, the adsorbent canbe within a cavity in the medical device (i.e. housed in the device)e.g. the adsorbent can be situated inside the cap or inside the body ofa dry-powder inhaler (see FIG. 3). Also, the adsorbent can be acomponent of the device e.g. the cap of a dry-powder inhaler cancomprise an adsorbent polymer mixture (see FIG. 3). Also, the adsorbentcan be affixed to the device in the form of an adhesive sticker/tapecomprising the adsorbent. Furthermore, the adsorbent can be separatefrom the device in an enclosed volume within which the device issituated (see FIG. 2).

The adsorbent can also be in the form of an adsorbent incorporated intoan adhesive (e.g. a self-adhesive patch or tape), in the same, orsimilar, manner as adhesive desiccants disclosed in U.S. Pat. No.6,103,141, which is incorporated herein by reference in its entirety.

The adsorbent material of the invention can also be in the form of anadsorbent in a porous sachet. Although it is not necessary to have asachet to contain the adsorbent within the package, a sachet clearly hasapplications herein. The adsorbent sachets are commercially availablefrom many suppliers including Sud-Chemie (Middlewich, England). Thesachet, with a “tea-bag” like appearance, is generally manufactured fromsynthetic fibers, such as polyamide or polyester fibers or blendsthereof. Commercially available materials suitable for making adsorbentsachets include, for example, GDT-II from San-ei Corporation (Osaka,Japan) and Tyvek from Perfecseal (Londonderry N. Ireland U.K.). However,a suitable sachet may be in other convenient shapes or appearances andmade from other permeable materials. Examples of adsorbents are selectedfrom the group consisting of molecular sieves, activated clays,activated alumina, silica, zeolites, bauxites, and mixtures thereof. Ina particular embodiment, the adsorbent material is 10 Å (Angstrom)molecular sieves. The amount of sieves to be used in the invention canbe readily calculated by a person skilled in the art, for example bytaking into consideration the amount of moisture to be absorbed, thepore size of the molecular sieve and the internal volume of the package.In a particular embodiment of the present invention, about 0.8 grams toabout 10 grams of molecular sieves is an effective amount, and moreparticularly, 0.8 grams to about 4.0 grams is an effective amount.Molecular sieve material is commercially available from severalmanufacturers. For example AtoFina (Solihull, England) market amolecular sieve under the trade name of Siliporite. More detailedtechnical information about molecular sieves and their other industrialuses can be found in the Molecular Seives: Unique Moisture andOdor-Taste Control Material”, D. Hajdu, T. J. Dangieri and S. R. Dunne,TAPPI Polym., Laminations Coat. Conf. (1999), Vol. 2, p. 655-662, whichis incorporated herein by reference in its entirety.

The term “effective amount of an adsorbent material” as used herein isintended to encompass the amount of an adsorbent material that isnecessary to be effective in reducing formation of Maillard products.The effective amount of adsorbent will depend on a number of factors,including the type of adsorbent and the moisture content of thepharmaceutical product. A person skilled in the art would readily beable to determine the effective amount of the adsorbent.

While there have been described and pointed out fundamental novelfeatures of the invention as applied to a particular embodiment thereof,it will be understood that various omissions and substitutions andchanges, in the form and details of the packages, adsorbents,pharmaceutical products and methods illustrated, may be made by thoseskilled in the art without departing from the spirit of the invention.For example, it is expressly intended that all combinations of thoseelements and/or method steps which perform substantially the samefunction in substantially the same way to achieve the same results arewithin the scope of the invention.

The present invention may be better understood by reference to thefollowing non-limiting Examples, which are provided as exemplary of theinvention. The following Examples are presented in order to more fullyillustrate particular embodiments of the present invention. They shouldin no way be construed, however, as limiting the broad scope of thepresent invention.

Example I Preparation of a Stable Pharmaceutical Product of theInvention

A. Stable Pharmaceutical Product Comprising and Formoterol FumarateDihydrate and an Additional Medicament

The additional medicament of this example can be any medicamentdiscussed above.

-   1. Deaggregate lactose monohydrate, formoterol fumarate dihydrate,    and the additional medicament (separately).-   2. Add both the lactose monohydrate and the additional medicament    into the mixing drum of a high shear mixer.-   3. Mix composition using a blender for about 4 minutes.-   4. Remove a portion of the powder (e.g. 100 g) and add to formoterol    fumarate dehydrate.-   5. Blend the formoterol fumarate dehydrate with the additional    medicament/lactose mixture in a blender.-   6. Return the pre-blend to the remainder of the blend in the    high-shear mixer.-   7. Blend for a further e.g. 4 minutes.-   8. Fill the blend into a dry powder inhalation device using a    suitable filling machine.-   9. Wrap the dry powder inhalation device with molecular sieves    inside a laminate foil overwrap (i.e. package).    Stability Testing

Using the procedure discussed above, and ciclesonide as the additionalmedicament, a blend of ciclesonide (19.97 mg/g), formoterol fumaratedihydrate (0.3 mg/g) and lactose monohydrate (979.70 mg/g) were blendedin a mixer for several minutes. The blend was filled into an AventisULTRAHALER dry powder inhalation device using a filling machine, and thedevice was wrapped in a laminate foil overwrap with a molecular sievesachet. The product was stored at 40 degrees Celsius and 75% relativehumidity, for 10 weeks and the amount of degradation measured by HPLCusing the following analytical conditions:

Column: Hipersil BDS-C18, 5 μm particle size, 150 mm×4.6 mm i.d.

-   Column temperature: Ambient-   Mobile phase A composition: 30% Ammonium Acetate (pH 8.0±0.05), 55%    Water, 15% Acetonitrile-   Mobile phase B composition: 300 Ammonium Acetate (pH 8.0±0.05): 750    Acetonitrile

Gradient Time Table Time (min) % A % B 0 100 0 10 100 0 20 87 13 30 7030 40 70 30 40.1 0 100 53.0 0 100 53.1 100 0

-   Flow rate: 1.0 ml/minute-   Detection: 250 nm-   Injection volume: 200 μl-   Total run time 60 minutes (time between 2 injections):-   Typical retention time of formoterol Approximately 18 to 19 minutes    fumarate dihydrate    Results:

Only two degradants, above the reporting threshold, were formed onstorage at Relative Retention Time (RRT)=1.35 and RRT 1.82 at levels of1.42 and 1.01% area respectively (these were identified as non-Maillardproducts). This is in stark contrast to 8 degradants that wereidentified when the same product is stored at 40 degrees Celsius and 75%relative humidity, without an overwrap and molecular sieve. The largestdegradant observed was at RRT=1.12 (1.42% area) in the product stored at40 degrees Celsius and 75% relative humidity without an overwrap andmolecular sieve. The results of this stability test are shown in FIG. 1.

The above study result demonstrates that inclusion of an adsorbentmaterial and the substantially moisture impermeable sealed package is asimple and effective solution to the problem of Maillard productformation occurring when a medicament and reducing sugar in a dry powderinhaler are in contact with each other in the presence of moisture.Particularly, molecular sieves are effective adsorbent materials againstMallard product formation caused by Formoterol and lactose in thepresence of moisture.

B. Stable Pharmaceutical Product of Formoterol Fumarate Dihydrate

In this example, a pharmaceutical product having only formoterolfumarate dihydrate as the medicament was produced with a reducing sugar.A process for producing a total quantity of 20 kg blend that contains5.4 g of formoterol fumarate dihydrate and 19994.6 g of lactosemonohydrate is as follows:

Blending Process

-   1. Lactose monohydrate and formoterol fumarate dihydrate are    screened to remove aggregate particles.-   2. The required quantities of each material are weighed out.-   3. 5.4 g of formoterol fumarate dihydrate and approximately 100 g of    the deaggregated lactose monohydrate are blended to form a    “pre-blend”.-   4. The pre-blend is then added to the remaining 19894.6 g of lactose    monohydrate in a blender. The powder mix is blended to form a final    homogeneous powder blend.    Manufacture of Formoterol DPI ULTRAHALERs

The final powder blend is filled into dry powder inhaler (DPI)components using a purpose-built mechanical filling and assemblymachine.

In a particular embodiment, the DPI filled with this stablepharmaceutical product is the ULTRAHALER from Aventis Pharma, UK. Afterbeing filled, the ULTRAHALER was overwrapped with a laminate foiloverwrap to form a sealed package. A sachet containing about 4 g ofmolecular sieves was also contained within the sealed package. Pursuantto the present invention, the level of impurities that develop withinthe DPI due to the Maillaird reaction clearly are less than the levelsof impurities that develop in absence of the laminate foil overwrap andthe molecular sieves. Data to support this observation are set forth inTable 1 below, which shows a similar extent of degradation after 2 and 6months storage at 25° C./75% RH when stored without an overwrap andsieve and when stored with these components, respectively.

TABLE 1 Assay mg/g (% of nominal) Product Initial 2 months 6 monthsFormoterol fumarate 0.255 (100) 0.240 (94) 4.5 mcg/actuation insideoverwrap containing molecular sieve Formoterol fumarate 0.255 (100)0.223 (87) 4.5 mcg/actuation

Although there are various types of adsorbent materials available andtheir effectiveness against any given gaseous substance variesconsiderably, it is understood that people of ordinary skill in the artcan easily adopt the above-described example to determine the type andthe amount of an adsorbent material that is effective in reducingformation of medicament adducts for any other types medical devicescontaining other different medicaments.

Example II Presence of Excess Hydrophobic Medicament Protects the FineParticle Fraction of a Hydrophilic Medicament

In this example, ciclesonide was used as the hydrophobic medicament, andformoterol fumarate dihydrate was used as the hydrophilic medicament.Three separate ULTRAHALERs were filled, respectively, with threeseparate formulations of ciclesonide and formoterol fumarate dihydrate.The three formulations are:

-   -   (1) 80 mcg ciclesonide: 4.5 mcg formoterol fumarate dihydrate        per actuation (ratio of about 20:1);    -   (2) 160 mcg ciclesonide:4.5 mcg formoterol fumarate dihydrate        per actuation (ratio of about 40:1); and    -   (3) 320 mcg ciclesonide:4.5 mcg formoterol fumarate dihydrate        (ratio of about 80:1).

An ULTRAHALER filled with the control formulation of 4.5 mcg formoterolfumarate dihydrate was also prepared. Each of these ULTRAHALERs wasoverwrapped with a sealed protective foil overwrap that also contained asachet of molecular sieves.

Initially, the percentage of fine particle fraction (mass <5.8 microns,expressed as a % of dose) was measured in each ULTRAHALER DPI before itsremoval from the overwrap (initial measurement). The ULTRAHALERs werethen stored for two (2) months at conditions of 25° C., 75% relativehumidity (RH). The percentage of fine particle fraction was measured ineach ULTRAHALER at one month and two months. These measurements are setforth in Table 2 below:

TABLE 2 Timepoint Formulation Initial 1 month 2 months FormoterolFumarate Fine Particle Fraction (%) 80 mcg ciclesonide: 35 33 31 4.5 mcgformoterol fumarate/actuation 160 mcg ciclesonide: 32 40 32 4.5 mcgformoterol fumarate/actuation 320 mcg ciclesonide: 32 40 36 4.5 mcgformoterol fumarate/actuation 4.5 mcg formoterol 33 23 19 fumarate(mono)

According to the data of Table 2, the fine particle fraction offormoterol fumarate dihydrate in the presence of ciclesonide remainedcomparable (in one case equal and in another even greater), with theinitial measurement taken from an ULTRAHALER within the laminateoverwrap with a sachet of molecular sieves, even after two months theULTRAHALER had been removed from the overwrap and stored at 25° C., 75%relative humidity. In contrast, the formoterol fumarate dihydrate fineparticle fraction in the control formulation that lacked ciclesonidedecreased approximately 42% as compared to its initial measurement.

This example demonstrates that the presence of a hydrophobic medicamentin an excess of 5:1 with respect to the presence of a hydrophilicmedicament in a pharmaceutical composition substantially protects thefine particle fraction of hydrophilic medicament following the removal adry powder inhaler containing the pharmaceutical composition from asealed package that also contains an adsorbent material.

The present invention is not to be limited in scope by the specificembodiments describe herein. Indeed, various modifications of theinvention in addition to those described herein will become apparent tothose skilled in the art from the foregoing description and theaccompanying figures. Such modifications are intended to fall within thescope of the appended claims.

Various publications are cited herein, the disclosures of which areincorporated by reference in their entireties.

What is claimed is:
 1. A stable pharmaceutical product for treating arespiratory disease or disorder, comprising i) a pharmaceuticalcomposition in the solid state, comprising a reducing sugar and one ormore medicaments having a propensity to form a Maillard product when incontact with a reducing sugar; ii) an effective amount of an adsorbentmaterial; and iii) a sealed package substantially impermeable tomoisture having an enclosed volume within which the pharmaceuticalcomposition and the adsorbent material are situated, wherein saidpharmaceutical composition comprises a hydrophobic medicament incombination with a hydrophilic medicament in a ratio of at least 5:1. 2.The stable pharmaceutical product of claim 1, wherein the ratio ofhydrophobic medicament to hydrophilic medicament is from about 10:1 toabout 100:1.
 3. The stable pharmaceutical product of claim 1, whereinthe hydrophobic medicament is a corticosteroid and the hydrophilicmedicament is a beta2-agonist.
 4. The stable pharmaceutical product ofclaim 1, wherein the hydrophobic medicament and the hydrophilicmedicament have a particle size of about 0.1 μm to about 10 μm.
 5. Thestable pharmaceutical product of claim 4, wherein greater than about 95%of the particles have a size of less than about 5 μm.
 6. The stablepharmaceutical product of claim 1, wherein the reducing sugar isselected from the group consisting of lactose, glucose, mannose,galactose, maltose, xylose, cellobiose, mellibiose, and maltotriose. 7.The stable pharmaceutical product of claim 1, wherein the adsorbentmaterial is selected from the group consisting of a molecular sieve, anactivated clay, charcoal, an activated alumina, silica, a zeolite, abauxite, and a mixture thereof.
 8. The stable pharmaceutical product ofclaim 1, wherein the adsorbent material is 10 Å (Angstrom) molecularsieves.
 9. The stable pharmaceutical product of claim 1, wherein thesealed package is a flexible laminate.
 10. The stable pharmaceuticalproduct of claim 1, wherein the sealed package is hermetically sealed byheat-sealing, gluing, welding, brazing, mechanical closures, mechanicalclamps, or compression.
 11. The stable pharmaceutical product of claim1, wherein the effective amount of the adsorbent material is that amountto eliminate or reduce formation of Maillard products.
 12. The stablepharmaceutical product of claim 1, wherein the reducing sugar islactose.
 13. The stable pharmaceutical product of claim 1, wherein thereducing sugar is lactose monohydrate.
 14. The stable pharmaceuticalproduct of claim 13, wherein the lactose monohydrate is non-micronised.15. The stable pharmaceutical product of claim 1, wherein thepharmaceutical composition is housed within a dry powder inhaler. 16.The stable pharmaceutical product of claim 15, wherein said adsorbentmaterial is incorporated into a polymer mixture and manufactured into aplastic component of said dry powder inhaler.
 17. The stablepharmaceutical product of claim 1, wherein said adsorbent material isincorporated into an adhesive.
 18. The stable pharmaceutical product ofclaim 1, wherein said adsorbent material is in a porous sachet.